Yokogawa UP550 Data sheet

<<Contents>> <<Index>>

General Specifications

MODEL UP550 Program Controller

GS 05E01C02-01E

■General

Model UP550 Program Controller can store up to 30 program patterns, and has a powerful control capability and the user-friendly large numerical display. The UP550 features as standard many functions which are necessary for various control applications, and all of these functions such as program setting function, control function, control computation function, signal computation function, etc. can be configured by using the keys on the front panel. The instrument has five types of control strategies, and also an overshoot suppressing function "SUPER" and a heating suppressing function "SUPER 2" built in as standard, as well as an auto-tuning function.

■Main Features

• Extra-large digital display allows the indicated values to be read even from a long distance. LEDs of 20 mm height are used for the process variable display. This is a five-digit display for heigher resolution.

• User-friendly, full-dot LCD display, capable of showing not only control setpoints (SPs) and parameters but also program patterns and deviation (DV) trend logs.

• Program setting function with storage capacity for up to 30 program patterns and 300 program segments, allowing the controller to be used for a wide range of heat-treatment applications.

• Five types of control function, including single-loop control, cascade control, loop control with PV autoselector, enabling the operator to start control operation immediately after simply entering the settings.

• The program pattern-2 retransmission function outputs a program pattern by way of the retransmission output. This function is used in combination with retransmission output setup parameter RET 1 or RET 2, for which program pattern-2 should selected, and is used for pattern transmission to another instrument(available for UP made 1, 2, 6 or 7).

• Parameters and program patterns can be easily set using a personal computer. ("Parameter setting tool (model LL100)" sold separately is required.)

• Universal input and output enables users to set or change freely the type of measured inputs, measurement input range, type of control output, etc. from the front panel.

• Contact inputs (up to 7 points) and contact outputs (up to 7 points) can be employed and functions can be assigned to each contact (the maximum number of points varies depending on the specification code), with one additional contact input available by specifying the appropriate suffix code. (Contact outputs can be increased up to eight; see "Number of Event/Alarm Outputs" on page 2 or "Contact Outputs" on page 7.)

• Various communication function are provided. Communication is possible with personal computer, programable logic controller, and other controllers.

UP550

UP550E

“E” indicates with the model with expanded functions.

■Functional Specifications

● Program Setting Function

The program setting function increases or decreases the value of a target setpoint (SP) according to a given program pattern that varies with time. The controller stores two or more program patterns and the operator can switch between them according to the operating status. Each program pattern consists of multiple line segments (program segments). The operator sets the time interval of each program segment using the segment time or slope. The operator can also set such instructions as the number of repeats, start/stop, and status output (event output) for a given program pattern.

Number of program patterns: 30 maximum Number of program segments per pattern: 99 maximum Number of program segments: 300 maximum (sum of

Configurable number of events: 400 maximum (sum of Number of program repeats: Segment time: 0 minute 0 s to 59 minute 59 s, o r 0 h 0 Start/stop of program pattern:

Switching between program patterns:

Target setpoint (SP)

Segment time

segments for all program patterns) events for all program patterns) 999 maximum, or unlimited repeats. minute to 99 h 59 minute. Program patterns can be started (RUN),

stopped (RESET), paused (hold) or advanced by means of contact inputs or from instrument operation.

Achieved by contact inputs or from instrument operation.

1 t2 t3 t4 t5

Segment No. 1

Example of Program Pattern

Segment No. 2

Segment No. 5

GS 05E01C02-01E

1st Edition Mar. 2000 (YG)

<<Contents>> <<Index>>

Wait Function

The wait function delays the execution of a program pattern when a process-variable (PV) input fails to keep track of changes in the given target SP. The wait function has two parameters: a wait zone and a wait time. The wait zone is a margin of deviation that is used to judge how precisely the PV input is tracking. The wait time is the time to wait for a PV input to reach the wait zone. If a PV input reaches the wait zone within the given wait time, the program advances to the next segment. Even if the PV input fails to reach the wait zone within the given wait time, the program also advances to the next segment when the wait time elapses.

Wa it time: OFF, or 0 minute 1 s to 99 minute 59 s or

0 h 1 minute to 99 h 59 minute.

Wait zone: 0 to 10% of measured input range width.

UP Modes and Program Setting Function

The UP modes with a single program setting function are:

Single-loop control, cascade primary-loop control, loop control with PV switching, loop control with PV auto-selector, and cascade control. Note that, in cascade control, the program setting function acts on the primary-loop only.

Program Setting Function and PID Parameters

Switching

The controller can switch between PID parameter sets as a program pattern progresses.

Segment PID selection:

PID-parameter numbers being used can be selected on a segment basis.

Zone PID selection:

PID parameter sets are switched depending on the value of the applied PV input. Either the reference point method (reference point: a setpoint for switching between PID parameter sets) or the reference deviation method is used for the switching.

Reference point method:

Divides the measuring input range into as many as seven zones using a maximum of six reference points, and switching between PID parameter sets is done on a zone basis.

Reference deviation method:

Switches between PID parameter sets depending on whether the control deviation (DV) is within the given reference deviation or exceeding the deviation. This method has priority over the reference point method during operation.

Time Events

The time event function notifies the progress of a program pattern, such as the time when the program moves from one segment to another, by means of an indicator lamp or contact output.

Configurable number of time events: Max.8 points Time event setpoint:

Allows the controller to output a time event ON or OFF after the lapse of a specific time from when the program switches from one segment to another. The lapse of time is configurable between 0 minute 0 s and 99 h 59 minute.

Number of time event indicator lamps: 4 points (TME 1, 2,

3, 4)

PV Events

The PV event is a PV/DV alarm function defined within a given program pattern.

Configurable number of PV events: 8 points maximum PV event indicator lamps: 2 points (PVE1 and PVE2) Event types: PV high limit, PV low limit, Deviation high

limit, Deviation low limit, Deenergized on deviation high limit, Deenergized on deviation low limit, Deviation high and low limits, High and low limits within deviation, Deenergized on PV high limit, Deenergized on PV low limit, SP high limit, SP low limit, Output high limit, Output low limit.

Configurable ranges of PV events:

PV alarm: -100 to 100% of measured input range DV alarm: -100 to 100% of measured input range width Alarm hysteresis: 0.0 to 100.0% of measured input range width

Instrument Alarm Functions

The instrument alarm function outputs PV, deviation, SP, and other alarm without regards to the program pattern. Controller has four instrument alarm outputs.

Alam types: PV high limit, PV low limit, Deviation high

Alarm setting range:

PV/SP alarm: -100 to 100 % of measured input range. Deviation alarm: -100 to 100 % of measured input range width. Output alarm: -5.0 to 105.0 % of output value. Alarm hysteresis: 0.0 to 100.0 % of measured input range width.

Stand-by action:

Stand-by action can be set to make PV/ deviation alarm OFF during start-up or after SP change until SP reaches the normal region.

Other alarm actions:

Sensor grounding alarm: Detects sensor deterioration and outputs an alarm. Fault diagnostic alarm: Input burnout, A/D conversion error, RJC error FAIL output: Abnormality in Software, Abnormality in

Hardware Number of Instrument Alarm Settings: 4 points Number of Instrument Alarm Outputs: Max. 4 points

One of PV alarm/Deviation alarm, Fault

diagnostic alarm, Sensor grounding alarm and

Fail output can be output with contact output.

(Note): Refer to the later "Contact Outputs" in

Hardware Specifications.

GS 05E01C02-01E 1st Edition Mar. 31, 2000-00

<<Contents>> <<Index>>

Number of Event/Alarm Output

(See "Contact Output," later in this brochure.)

• As many as seven event and instrument alarms in combination can be output using contact outputs (standard feature). (Note that a control output relay can be used as the output device of time event number 5. This increases the number of contact outputs to eight.)

• Number of contact (relay) outputs:

3 (standard), or 4 (if a control output relay is used as the output device of time event number 5)

• Number of contact (open-collector transistor) outputs:

4 (standard)

From the above, up to 8 point outputs can be obtained.

• Any of Time Events, PV Events and Instrument Alarm function can be assigned to contacts for the above number of outputs. However, the timer delay alarm can be assigned to the first alarm output only. Also, the fifth time event is assignable only to the control output relay. Events and the alarm status can be read via communication in addition to output as the above alarm output.

• The controller is shipped from the factory with the following settings:

Number of time events: 4 Number of PV events: 2 Number of instrument alarms: 1

● Control Functions

UP Mode

The following types of basic control can be set as the UP mode by the user.

Single-loop control (UP mode 1):

The most simple and basic control function.

Cascade primary-loop control (UP mode 2):

Output tracking function and cascade control logic are provided. Suitable for primary-loop cascade control.

Cascade control (UP mode 4):

Dual control function for cascade control in a single instrument.

Loop control with PV switching (UP mode 6):

Two measured inputs are switched for control depending on the value of contact input or measured input.

Loop control with PV auto-selector (UP mode 7):

Two measured inputs are automatically selected for control with a high, low, average or temperature-difference selector.

● Control Computation Functions

In each UP mode, the following types of control computation can be selected:

Continuous PID control, Time proportional PID control, Position proportional PID control (for UP550-1■), Relay ON/OFF control, and Heating/Cooling control (for UP550-2■).

Number of PID parameter sets:

Up to eight sets can be set; eight sets each for the main loop and slave loop in the case of cascade control.

Auto-tuning: Available as standard. Possible to activate

auto-tuning for both main and slave loops for cascade control.

"SUPER" function:

Overshoots generated by abrupt changes in the target setpoint or by disturbances can be suppressed.

"SUPER 2" function:

This function stabilizes the state of control that is unstable due to hunting, etc. without requiring any change in PID constants, when the load and/or gain varies greatly, or when there is a difference between the characteristics of temperature zones.

Preset output function:

When the instrument is in Stop mode, measured input is burnt-out, or an abnormality is found in an input circuit, a preset setpoint is output as a control output.

Control cycle time

Each cycle time can be selected under the following conditions:

100 ms: Available when UP mode is not cascade

control (UP mode 4).

200 ms: Available when UP mode is cascade control

(UP mode 4).

(Set value when shipped from the factory: 200 ms)

Operation Mode Switching

(Note: Communication enables all the following

mode switching to be executed.)

AUTO/MANUAL switching:

Bumpless switching between automatic operation mode and manual control mode is available by using instrument operation or contact input. The contact input has priority over instrument operation or switching by communication.

RUN (PRG)/STOP (RESET) switching:

Bumpless switching from Run to Stop mode is available by using the front key or contact input. The contact input has priority over the front key or switching by communication. Control computation is valid in Run mode but not in Stop mode. The preset value is output as a control output. Other functions operate normally.

CASCADE/Local SP switching:

Switching between the cascade, automatic and manual operating modes is available by using instrument operation or contact input when in Cascade control. The contact input has priority over instrument operation or switching by communication.

Control Parameters Setting Range

Proportional band: 0.1 to 999.9%

0.0 to 999.9% (for heating/cooling PID

control), 0.0% available for ON/OFF control. Integral time: 1 to 6,000 s, or OFF (for Manual reset) Derivative time: 1 to 6,000 s, or OFF ON/OFF control hysteresis: 0.0 to 100.0% of measured

input range width Preset output value: -5.0 to 105.0% (0 mA or less cannot

be output) Output limiter:

Setting range: -5.0 to 105.0% for both high

and low limits

However, "low limit setpoint < high limit

setpoint" must be satisfied.

In case of heating/cooling PID control, upper

limiter for heating and upper limiter for

cooling.

<<Contents>> <<Index>>

Shutdown function:

When manual control is carried out with 4 to 20 mA output, control output can be output down to about 0 mA (shutdown is specified

for -5.0% or less). Rate-of-change limiter for output: OFF or 0.1 to 100.0%/s Deadband for heating/cooling control: -100.0 to 50.0% for

output value Deadband for position-proportional control: 1.0 to 10.0%

for output

● Configuration of Input/Output Signal

Measured Input Computations

Input processing, Square root extraction (voltage input only, Input low cut 0.0 to 5.0%), Ten-segment linearizer function, Segment bios, Bias addition (-100.0 to 100.0%), and First order lag filter (off, time constant 1 to 120 s)

Auxiliary Input Computations

Input processing, Square root extraction (Input low cut 0.0 to

5.0%), Bias addition (-100.0 to 100.0%), Ratio multiplication (0.001 to 9.999), First order lag filter (OFF, time constant 1 to 120 s)

● Display and Operation Functions

PV Display

The controller display either PV1 or PV2 (only during cascade control), when switched, on the 5-digit display.

The number of display digits is 4 or 5. For thermocouple or RTD, data below the decimal point can be set not to display. The display range is -19999 to 30000 and the display span is 30000 or less. [550.00 appearing in the product photograph on page 1 cannot actually be displayed.]

LCD Display

Some data are displayed on LCD display unit. Each screen is called “display”.

Five types of display are provided; Operating display, Operating parameter setting display, Program parameters setting display, Setup parameter setting display and SELECT display.

Operating display:

Necessary data for operation is displayed

according to UP mode.

Such items as Pragram pattern, Setpoint,

Control Ouput, control output bar, deviation

trend is displayed. Time base of deviation trend is 120 s to 20 h.

Operating parameters setting display:

The Operating paramters, which are mainly changed during operation, such as PID constant, are displayed.

Program Parameters Setting display:

Setting of Program pattern, stand-by action, parameters of Repeat action are displayed.

Setup Parameters Setting display:

The Setup parameters to configure functions of the instrument before starting operation are displayed. The explanation of each parameters is provided. UT mode is set in this display.

SELECT display:

Up to five displays which are frequently accessed can be selected from Operating parameter setting display and Setup parameters setting display.

Status Lamps

Event indicator lamps:

Seven lamps, TME1, TME2, TME3, TME4, PVE1, PVE2, and AL1

Operation mode indicator lamps:

PRG (program operation), RST (operation at a stop), HLD (operation hold), LOC (local setting), MAN (manual operation), CAS (cascade operation), and PV2 (process variable 2)

Operation Keys

▲, ▼keys: Increase or decrease setpoints and other

parameters displayed on the LCD display.

DISP key: Switches from one data value to another on

the LCD display.

SET/ENT key: Used for setting or changing set data,

switching the LCD displayed contents, and

switching operation modes except for A/M. MODE key:Switches between the operating modes. 䉮PT. No 䉭 key:

Selects the pattern number. RUN key: Initiates the program operation. RESET key: Stop and reset the program operation.

Security Function

Key-lock from parameter setting and,

operation can be inhibited by a password.

Status lamps

Indicates PV2 reading (PV2), time events (TIME1 to TIME4), PV events (PVE1 and PVE2), instrument alarm (AL1), program operation (PRG), stop of program operation (RST), operation hold (HLD), local operation (LOC), manual operation (MAN), and cascade operation (CAS).

Communication port for light loader

Parameters and programs are set via communication from a personal computer.

Operation keys

Increase/decrease the setpoint values (▲, ▼), switch between displays (DISP), switch between operation modes (MODE), select between parameters/set values (SET/ENT), switch between program patterns (䉭PT. No䉮 ), start program operation (RUN), and stop program operation (RESET).

Measured value (PV) display unit

Displays PV and error codes when errors are detected.

LCD display unit

Displays the setpoint value (SP), program pattern, output value, bar graph (of deviations), deviation, deviation trend, valve opening, and the setting item and setting value of a parameter, etc.

GS 05E01C02-01E

1st Edition Mar. 31, 2000-00

<<Contents>> <<Index>>

Examples of Communication System Configuration Diagram

(1) Personal computer link communication/

MODBUS communication

Personal computer

PV2

REM

MAN1

MAN2

STP

CAS

A/M

DISP

SET/ENT

UP550 program controller

PV2

1 2

REM

MAN1

MAN2 STP CAS

A/M

DISP

SET/ENT

PV2

1 2

REM

MAN1

MAN2 STP CAS

A/M

DISP

SET/ENT

(2) Ladder communication (3) Coordinated operation

MELSEC-A

Programmable controller

PV2

1 2 3

REM

MAN1 MAN2 STP CAS

A/M

UP550 program controller

PV2

1 2 3

REM

MAN1 MAN2 STP CAS

A/M

DISP

SET/ENT

DISP

SET/ENT

UP550 (or UP750) program controller

PV2

1 2

REM

MAN1

MAN2 STP CAS

A/M

DISP

SET/ENT

PV2

1 2 3

REM

MAN1 MAN2 STP CAS

A/M

DISP

SET/ENT

PV2

REM

MAN1 MAN2 STP CAS

A/M

DISP

SET/ENT

PV2

1 2

REM

MAN1

MAN2 STP CAS

A/M

DISP

SET/ENT

PV2

REM

MAN1

MAN2

STP

CAS

A/M

DISP

SET/ENT

PV2

1 2 3

REM

MAN1 MAN2 STP CAS

A/M

DISP

SET/ENT

UT750, UT550, UT520, UT350 or UT320 digital indicating controller

Input type

Input range

code

Unspecified (When shipped from the factory) Thermocouple

typeK1 (1) typeK2 (2)

typeK3 (3) J T

typeJ (4)

typeT1 (5)

typeT2 (6) B

S R N

E L (DIN) U (DIN)

typeB (7)

typeS (8)

typeR (9)

typeN (10)

typeE (11)

typeL (12)

typeU1 (13)

typeU2 (14)

typeW (15)

plati2 (16)

PR2040 (17)

W97Re3 (18)

JPt1 (30)

RTD

W Platinel 2 PR20-40

W97Re3-W75Re25 JPt100

JPt2 (31) Pt100

Pt1 (35)

Pt2 (36)

Pt3 (37)

Standard signal

DC voltage

0.4 to 2V 1 to 5V 0 to 2V 0 to 10V

-10 to 20mV 0 to100mV

0.4 to 2V (40)

1 to 5V (41)

0 to 2V (50)

0 to 10V (51)

mV1 (55)

mV2 (56)

OFF

Instrument

range (°C)

Instrument

range (°F)

Instrument accuracy

Set the data item PV input type “IN 1” to the OFF option to leave the PV input type undefined.

-270.0 to 1370.0°C

-270.0 to 1000.0°C

-200.0 to 500.0°C

-200.0 to 1200.0°C

-270.0 to 400.0°C

0.0 to 400.0°C

0.0 to 1800.0°C

0.0 to 1700.0°C

-200.0 to 1300.0°C

-270.0 to 1000.0°C

-200.0 to 900.0°C

-200.0 to 400.0°C

0.0 to 400.0°C

0.0 to 2300.0°C

0.0 to 1390.0°C

0.0 to 1900.0°C

0.0 to 2000.0°C

-200.0 to 500.0°C

-150.00 to 150.00°C

-200.0 to 850.0°C

-200.0 to 500.0°C

-150.00 to 150.00°C

0.400 to 2.000 V

1.000 to 5.000 V

0.000 to 2.000 V

0.00 to 10.00 V

-450.0 to 2500.0°F

-450.0 to 2300.0°F

-200.0 to 1000.0°F

-300.0 to 2300.0°F

-450.0 to 750.0°F

-200.0 to 750.0°F 32 to 3300°F

32 to 3100°F 32 to 3100°F

-300.0 to 2400.0°F

-450.0 to 1800.0°F

-300.0 to 1600.0°F

-300.0 to 750.0°F

-200.0 to 1000.0°F

32 to 4200°F

32.0 to 2500.0°F 32 to 3400°F

32 to 3600°F

-300.0 to 1000.0°F

-200.0 to 300.0°F

-300.0 to 1560.0°F

-300.0 to 1000.0°F

-200.0 to 300.0°F

Display range

-19999 to 30000 Display span 30000 or less (Decimal point position changeable)

±0.1% ±1 digit of instrument range at 0°C or more ±0.2% ±1 digit of instrument range at less than 0°C

• However, ±2% ±1 digit of instrument range for type K at temperatures less than -200°C. However, ±1% ± 1 digit of instrument range for type T

• at temperatures less than -200°C.

±0.15% ±1 digit of instrument range at 400°C or more ±5% ±1 digit of instrument range at less than 400°C

±0.15% ± 1 digit of instrument range

±0.1% ± 1 digit of instrument range ±0.25% ±1 digit of instrument range for temperature at less than 0°C

±0.1% ±1 digit of instrument range at 0°C or more ±0.2% ±1 digit of instrument range at less than 0°C

• However, ±1.5% ±1 digit of instrument range for type E at temperature less than -200°C.

±0.2% ±1 digit of instrument range ±0.1% ± 1 digit of instrument range

±0.5% ±1 digit of instrument range at 800°C or more

Accuracy not guaranteed for temperature less than 800°C

±0.2% ± 1 digit of instrument range ±0.1% ± 1 digit of instrument range (Note1) (Note2) ±0.2% ± 1 digit of instrument range (Note1) ±0.1% ± 1 digit of instrument range (Note1) (Note2)

±0.2% ± 1 digit of instrument range (Note1) ±0.1% ± 1 digit of instrument range

-10.00 to 20.00 mV

0.0 to 100.0 mV

Numbers in ( ) are the measurement input range codes that apply when the communication function is used.

*1: Performance in the standard operating conditions (at 23± 2°C, 55± 10% RH, and 50/60 Hz power frequency) Note 1:The accuracy is ±0.3°C of instrument range ±1 digit for a temperature range from 0 to 100°C Note 2:The accuracy is ±0.5°C of instrument range ±1 digit for a temperature range from –100 to 200°C.

1st Edition Mar. 31, 2000-00

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